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WINCH MOUNT INSTALLATION INSTRUCTIONS 1. Remove molded plastic bumper guard from the ATV. 2. Mount the winch mount weldment (Item 1) to the ATV as shown below. 3. Mount the roller hawse to the winch mount weldment as shown above. 4
4. Mount the winch to the winch mount weldment and route the winch cable through the rollers. (Installer may need to remove rollers to allow cable end to pass through). 5. Wire the winch according to the manufacturer instructions. 6. Re-install the molded plastic bumper guard. 5 *CAUTION BE AWARE OF WHEN THE CABLE STOP CONTACTS THE ROLLER HAWSE AS CABLE IS WOUND IN. FAILURE TO RELEASE MAY CAUSE DAMAGE TO WINCH PARTS OR TO THE ATV. When using the winch to raise and lower a blade a cable stop must be installed. Carefully raise the blade until the top of the push tube’s are no closer than 1″ anywhere on the ATV. Place the Cable Stop onto the Winch Cable up against the Winch Hawse. Secure the Cable Stop to the Winch Cable using the Cable Clamp Assembly as shown in the pictures below.

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FUEL AND OIL FUEL Proper fuel is very important for the engine. Ensure there is no dust, dirt, or water which has mixed in the fuel. Use regular unleaded gasoline with an octane number 90 or higher. ENGINE OIL Your 250cc ATV has a four-stroke engine. Please use oil as described in the chart below. By using prescribe oil, you will realize the best lubrication for engine. Use the chart to select a viscosity rating based on the temperature range in your area. NOTE: In very cold weather (below 5°F (-15°C), use SAE10W-30 for good starting and smooth operation. SAE 10W-30 SAE 20W-40 ENGINE TEMP. °C °F -30 -22 40 104 -10 14 0 32 10 50 20 68 30 86 -20 4 FUEL AND OIL 8 LOCATION OF LABELS Read and follow all of the warnings labels on your ATV. Make sure you understand all the labels. Keep the labels on the ATV. Do not remove them for any reason. If a label comes off or becomes difficult to read, you should get a replacement by contacting BAJA INC. 1 – Red Light – Reverse indicator Light illuminates when ATV is in Reverse. 2 – Green Light – Neutral indicator Light illuminates when ATV is in Neutral. 3 – Ignition key switch – Turn right (CW) “RUN”, Turn left (CCW) “OFF”. ATV will only start when ignition key is turned to the “RUN” position. Make sure ignition key switch is in the “OFF” position when not in use

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.

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Place jack under center on the ATV front end and lift until front wheels clear the ground. Be careful to support ATV properly so that it is secure, but so that the A-arms and shocks can droop to full extension. 2. Remove front wheels and shocks. 3. Using a shock spring compressor, compress the spring on the shock and remove the spring retaining ring.
CAUTION: The spring is installed under tension. Failure to use a shock spring compressor could cause loss of control of the spring, which could unload rapidly causing bodily injury. If you do not have a shock spring compressor you should acquire one or take it to a dealer or professional mechanic for installation of the stiffeners. 4. Remove the spring. 5. Insert the smaller front spring stiffener onto the shock with the lip of the spring stop, on the shock, mating into the recessed portion of the spring stiffener. 6. Slide the spring back onto the shock and it should rest on the lip of the spring stiffener.
7. Reattach the spring retaining ring. 8. Repeat steps for the opposite side. Once springs are complete reattach the top of the shock to the top shock mount on the ATV and the spring stiffener will be closest to the A-arm. 9. Take two of the “L” brackets and connect them to the bottom of the shock, the part that connects to the A-arms. 10. There is a top and bottom to the “L” bracket. See the diagram

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Begin by placing winch in freespool. Support the winch so that it will stand upright on the workbench, Fig. 1. This will ensure that the winch drivetrain will not be dislocated during disassembly. 2. Remove the two lower cap screws and nuts. Next remove the two upper cap screws, Fig. 2. Figure 2: Remove Cap Screws Figure 1: Position the Winch Upright Lower Cap Screws Upper Cap Screws Freespool Lever Position 3 Lift the gear housing straight up off the gears. Take care not to disturb the gear set. 4. Rotate the gear housing clockwise 90 degrees and place back down over the gear set. It may take slight twisting motion to have the housing align and drop over the gear set. 5. Align holes and replace hardware securing the endhousing back on the winch. Torque bolts to 45 in-lbs. The winch is now ready to be installed. Figure 3: Lift Gear Housing Figure 5: Reinstall Hardware Figuere 4: Rotate and Replace Gear Housing Rotate and Lower IV. Kymco MXU 250 Installation 1. Begin by removing the plastic bumper located on the front of the ATV. Remove the four front bolts and two bolts securing the bumper on the back side, Fig. 6. 2. Set the bumper aside. Save the fasteners to reinstall the bumper.

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apply or add designated greases and lubricants to the specified lubrication points. ÑAfter reassembly, check all parts for proper tightening and operation. ÑWhen two persons work together, pay attention to the mutual working safety. ÑDisconnect the battery negative (-) terminal before operation. ÑWhen using a spanner or other tools, make sure not to damage the motorcycle surface. ÑAfter operation, check all connecting points, fasteners, and lines for proper connection and installation. ÑWhen connecting the battery, the positive (+) terminal must be connected first. ÑAfter connection, apply grease to the battery terminals. ÑTerminal caps shall be installed securely. 1 . GENERAL INFORMATION 1-6 ATV 300/250 ÑIf the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. ÑAfter operation, terminal caps shall be installed securely. ÑWhen taking out the connector, the lock on the connector shall be released before operation. ÑHold the connector body when connecting or disconnecting it. ÑDo not pull the connector wire. ÑCheck if any connector terminal is bending, protruding or loose. Confirm Capacity 1 . GENERAL INFORMATION 1-7 ATV 300/250 ÑThe connector shall be inserted completely. ÑIf the double connector has a lock, lock it at the correct position. ÑCheck if there is any loose wire

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1. Remove the two 8mm bolts that attach the front bumper assembly to the ATV frame see figure 3. 2. Place Winch mounting plate (A1) into position and fasten the two bent down tabs to the ATV frame using the two 8mm bolts removed in step one, see figure 4, and figure 5. Do not tighten fully at this time. 3. Attach the front of the mounting plate using four 1/4-20 u- bolts (B1), eight lock washers (B2), and eight 1/4-20 hex nuts (B3), see figure 6. 4. Tighten all fastners for the mounting kit at this time. 5. Place winch into position behind the mounting plate. Attach the top two feet of the winch using two 5/16-18 hex cap screws and lock washer. These fasteners will be found in the hardware kit that came with the winch. Note: The winch has floating nuts in its feet. In some instances, a nut may be moved off to one side making it impossible to screw a bolt in. If this becomes the case, take a screwdriver and center the floating nut in the winch to the bolt hole opening. Now attach the bolt through the Winch Plate and into the winch. 6. If using a Cast Hawse Fairlead: It may be neccasary to remove the cast hawse fairlead from the fairlead mounting plate that came with the winch.

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Hi/Low Switch Installation Choose a location for the switch, which is convenient and has sufficient rear clearance for the electrical connections and is within 18″ of a voltage-controlled wire (a wire in the lighting circuit). Drill a 1/2″ (13mm) hole and install the switch from the back. Leave the strain relief nut on the switch. On the front install the Hi/Low indicator tab and secure the switch and tab using the metal nut. The amount of switch barrel protruding can be adjusted by moving the strain relief nut. Wire Routing and Connections Route the electric cord along the handlebar to switchmarea and secure with supplied tie wraps, electrical tape, or both. Cut and strip to proper length. Attach a ground wire of sufficient length to go from the red wire to a good ground. WARNING: Lead wire slack in the area of the throttle must be neither excessive nor tight. Ensure no binding occurs when the throttle is open fully.,Soldering connections is the most durable method, but the following will provide years of service. Attach the 1/4″ female slip-on connectors to the white and blue wires and #10 ring terminal to warmer leads as shown in Figure 2. (A crimping tool works best, but a Vise Grips or pliers will work). Figure 2. Switch Connections (Option B) Connect the single yellow or red wire to a regulated (lighting) circuit using Option A (ATV has a switch in a lighting circuit with a 1/4″ tab) or Option B: Option B: Locate a power wire (usually yellow) leading to a headlight, taillight, or dash light (Figure 2). Using the red tap connector, place this power wire into the continuous channel and insert the red wire (do not strip insulation) completely to stop in the second channel. Make the connection by squeezing (w/pliers) the metal contact until flush with the top of the connector. Close the hinged cover until latched. Complete connections to switch and ground circuit.